Next-Generation Custom-Fit Reusable Respiratory Protective Device with Continuous Fit Monitoring - Part III: 3D...

Area of Science:

• Biomedical Engineering
• Materials Science
• Additive Manufacturing

Background:

• Standard respiratory protective devices (RPDs), like filtering facepiece respirators (FFRs), often come in limited sizes, posing fit challenges for diverse demographics.
• Existing RPDs may not adequately accommodate variations in facial features across different genders and races.

Purpose of the Study:

• To develop and create physical prototypes of a custom-fit RPD using 3D printing technology.
• To integrate a pressure-sensing network for continuous fit monitoring and alert system.
• To demonstrate the RPD's adaptability to dynamic facial movements and its potential for broader population coverage.

Main Methods:

• Digital prototypes were transformed into physical RPDs via 3D printing using silicone-based elastomers.
• Key material properties for prototype fabrication were identified and analyzed.
• Two commercial 3D printers and selected materials were used to create the RPD prototypes.

Main Results:

• The custom-fit RPD prototypes successfully conformed to user facial features and adapted to movements like talking, smiling, and yawning.
• A pressure-sensing network quantified changes in face seal pressure during use.
• An accompanying Android application provided real-time fit monitoring data.

Conclusions:

• The developed methodology enables the creation of successful custom-fit RPDs.
• This technology lays the foundation for enhanced respiratory protection and source control for all individuals, including children.
• The custom-fit RPD addresses limitations in current FFR options for specific demographic groups.